Conductive mat for battery electrode plate reinforcement and methods of use therefor

ABSTRACT

According to one embodiment, a plate or electrode for a lead-acid battery includes a grid of lead alloy material, a paste of active material applied to the grid of lead alloy material, and a nonwoven fiber mat disposed at least partially within the paste of active material. The nonwoven fiber mat includes a plurality of fibers, a binder material that couples the plurality of fibers together, and a conductive material disposed at least partially within the nonwoven fiber mat so as to contact the paste of active material. In some embodiments, the nonwoven fiber mat may have an electrical resistant of less than about 100,000 ohms per square to enable electron flow on a surface of the nonwoven fiber mat.

BACKGROUND OF THE INVENTION

Lead-acid batteries are characterized as being inexpensive and highlyreliable. As such, they are widely used as an electrical power sourcefor starting motor vehicles, golf carts, and other electric vehicles. Inrecent years, a variety of measures to improve fuel efficiency have beenconsidered in order to prevent atmospheric pollution and global warming.Examples of motor vehicles subjected to fuel-efficiency improvementmeasures that are being considered include idling stop vehicles (ISSvehicles) where the engine is stopped when the vehicle is not in motionto prevent unnecessary idling of the engine and to reduce engineoperation time.

In an ISS vehicle, the number of engine startup cycles is higher, andthe lead-acid battery discharges a large electrical current during eachstartup. In addition, the amount of electricity generated by thealternator in an ISS vehicle is smaller, and the lead-acid battery ischarged in an intermittent manner. As such, charging of the battery isoften insufficient. Stated differently, the battery is in a partiallycharged state known as a PSOC (i.e., partial state of charge).Accordingly, a lead-acid battery used in an ISS vehicle is required tohave a capability in which the battery is charged as much as possible ina relatively short time. In other words, the lead-acid battery shouldhave a higher charge acceptance. Therefore, improvements in the chargeacceptance of a lead-acid battery are desired.

Lead-acid batteries typically have a shorter lifespan when used underPSOC than in an instance in which the battery is used in a fully chargedstate. One reason for the shorter lifespan under PSOC is believed to bedue to repeatedly charging and recharging the battery in aninsufficiently charged state. Charging and recharging the battery inthis manner negatively affects the battery's electrodes or plates. Forexample, lead sulfate forms on the negative plate during discharge andundergoes progressive coarsening during charging and tends not to returnto metallic lead. Improving the charge acceptance may prevent thebattery from being charged and recharged in an insufficiently chargedstate, which may inhibit coarsening of lead sulfate due to repeatedcharging/discharging. This may increase the life span of the lead-acidbattery.

In addition, there are inherent disadvantages to lead-acid batteries.For example, during discharge of the lead-acid battery, the lead dioxide(a fairly good conductor) in the positive plate is converted to leadsulfate (an insulator). The lead sulfate can form an impervious layerencapsulating the lead dioxide particles which limits the utilization oflead dioxide to less than 50 percent of capacity, and more commonlyaround 30 percent. The low percentage of usage is a key reason why thepower and energy performance of a lead-acid battery is inherently lessthan optimum. It is believed that this insulator layer leads to higherinternal resistance for the battery. Improving the charge acceptance mayalso help reduce issues associated with formation of lead sulfate.

BRIEF SUMMARY OF THE INVENTION

The embodiments described herein provide nonwoven fiber mats that can beused to reinforce plates in lead-acid batteries and/or that have anelectrically conductive surface that enhances electron flow from thebattery plates. The nonwoven fiber mats described herein may improve thecharge acceptance of a lead-acid battery in addition to reinforcing thebattery's plates or electrodes. According to one embodiment, a lead-acidbattery is provided. The lead-acid battery may include a positiveelectrode, a negative electrode, a separator positioned between thepositive electrode and the negative electrode to electrically insulatethe positive and negative electrodes, and a fiber mat (reinforcementmat) that is positioned adjacent either the positive electrode or thenegative electrode to reinforce the positive or negative electrode. Theseparator may also include a nonwoven fiber mat that is used toreinforce the separator. The reinforcement mat may include: a pluralityof fibers, a binder material that couples the plurality of fiberstogether, and a conductive material that is disposed on at least onesurface of the reinforcement mat or throughout the reinforcement mat soas to contact the positive or the negative electrode. The reinforcementmat may have an electrical resistant of less than about 100,000 ohms persquare so as to enable electron flow on the surface or through thereinforcement mat.

In some embodiments, the reinforcement mat may have an electricalresistant of less than about 50,000 ohms per square. In someembodiments, the separator may also include a conductive material thatis disposed on at least one surface of the separator's fiber mat orthroughout the separator's fiber mat such that the separator's fiber matcomprises an electrical resistant of less than about 100,000 ohms persquare to enable electron flow on the surface of the separator's fibermat.

In some embodiments, the conductive material may include a plurality ofconductive fibers that are entangled with fibers of the reinforcementmat. In some embodiments, the binder material may include the pluralityof conductive fibers. In some embodiments, the plurality of fibers ofthe reinforcement mat may include glass fibers. In some embodiments, thereinforcement mat may be a first fiber mat that is positioned on a firstside of the positive electrode or the negative electrode and thelead-acid battery may also include a second fiber mat that is positionedon a second side of the positive electrode or the negative electrodeopposite the first side. The second fiber mat may include a conductivematerial disposed on at least one surface of the second fiber mat orthroughout the second fiber mat such that the second fiber mat has anelectrical resistant of less than about 100,000 ohms per square toenable electron flow on the surface of the second fiber mat.

According to another embodiment, a plate or electrode for a lead-acidbattery is provided. The plate or electrode may include a grid of leadalloy material, a paste of active material applied to the grid of leadalloy material, and a nonwoven fiber mat that is disposed at leastpartially within the paste of active material. The nonwoven fiber matmay include: a plurality of fibers, a binder material that couples theplurality of fibers together, and a conductive material that is disposedat least partially within the nonwoven fiber mat so as to contact thepaste of active material. The nonwoven fiber mat may have an electricalresistant of less than about 100,000 ohms per square to enable electronflow on a surface of the nonwoven fiber mat.

In some embodiments, the nonwoven fiber mat may be disposed within thepaste of active material between about 0.001 inches and about 0.020inches. In some embodiments, the nonwoven fiber mat may be a firstnonwoven fiber mat and the plate or electrode may also include a secondnonwoven fiber mat that is disposed at least partially within the pasteof active material on a side opposite the first nonwoven fiber mat. Insuch embodiments, the plate or electrode may be disposed between twononwoven fiber mats. In some embodiments, the two nonwoven fiber matsmay be opposite sides of a bag that encloses or envelopes the paste ofthe active material and the plate or electrode.

In some embodiments, the binder may be applied to the nonwoven fiber matbetween about 10% and 45% by weight, between about 20% and 30% byweight, and the like. In some embodiments, the binder may include theconductive material. In some embodiments, the nonwoven fiber mat mayinclude fibers selected from the group consisting of: glass fibers,polyolefin fibers, and polyester fibers. In some embodiments, theconductive material may include a plurality of conductive fibers thatare entangled with fibers of the nonwoven fiber mat.

According to another embodiment, a method of manufacturing a plate of alead-acid battery is provided. The method may include providing a gridof lead alloy material and applying a paste of active material to thegrid of lead alloy material to form a battery plate or electrode (i.e.,negative or positive electrode). A nonwoven fiber mat may be applied toa surface of the paste of the active material such that the nonwovenfiber mat is disposed at least partially within the paste of activematerial. The nonwoven fiber mat may include a plurality of fibers, abinder material that couples the plurality of fibers together, and aconductive material disposed at least partially within the nonwovenfiber mat so as to contact the paste of active material. The nonwovenfiber mat may have an electrical resistance of less than about 100,000ohms per square to enable electron flow on a surface of the nonwovenfiber mat. In some embodiments, the nonwoven fiber mat may be disposedwithin the paste of active material between about 0.001 inches and about0.020 inches.

In some embodiments, the method may also include applying a secondnonwoven fiber mat to an opposite surface of the paste of activematerial so that the grid of lead alloy material is disposed between twononwoven fiber mats. The second nonwoven fiber mat may also include aconductive material that is disposed at least partially within thesecond nonwoven fiber mat so as to contact the paste of active material.In some embodiments, the nonwoven fiber mat may have a thickness of0.009 inches or less and/or a tensile strength of at least 30 lbs/3inch.

In some embodiments, the plurality of fibers may include first fibershaving fiber diameters between about 6 μm and about 11 μm and secondfibers having fiber diameters between about 10 μm and about 20 μm. Insome embodiments, the binder may include the conductive material. Thebinder may be applied to the mat between about 10% and 45% by weight,between about 20% and 30% by weight, and the like. In some embodiments,the conductive material may include a plurality of conductive fibersthat are entangled with fibers of the nonwoven fiber mat.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is described in conjunction with the appendedfigures:

FIG. 1 illustrates an exploded perspective view of a battery cellassembly.

FIG. 2 illustrates an assembled cross section view of the battery cellassembly of FIG. 1.

FIGS. 3A-3C illustrate cross section views of various configurations ofan electrode or plate and a nonwoven fiber mat.

FIG. 4 illustrates a process for preparing an electrode or plate havinga nonwoven fiber mat disposed on or near a surface of the electrode orplate.

FIG. 5 illustrates a method of manufacturing a plate of a lead-acidbattery.

In the appended figures, similar components and/or features may have thesame numerical reference label. Further, various components of the sametype may be distinguished by following the reference label by a letterthat distinguishes among the similar components and/or features. If onlythe first numerical reference label is used in the specification, thedescription is applicable to any one of the similar components and/orfeatures having the same first numerical reference label irrespective ofthe letter suffix.

DETAILED DESCRIPTION OF THE INVENTION

The ensuing description provides exemplary embodiments only, and is notintended to limit the scope, applicability or configuration of thedisclosure. Rather, the ensuing description of the exemplary embodimentswill provide those skilled in the art with an enabling description forimplementing one or more exemplary embodiments. It being understood thatvarious changes may be made in the function and arrangement of elementswithout departing from the spirit and scope of the invention as setforth in the appended claims.

Embodiments of the invention provide nonwoven fiber mats (hereinafterconductive reinforcement mat or reinforcement mat) that can be used toreinforce plates in lead-acid batteries, or other batteries, and thathave an electrically conductive surface that enhances electron flow toand/or from the battery plates. The conductive reinforcement mats can beany woven or non-woven mat which is acid resistant, such as glass mat,or mat made from mainly polyolefin fibers, or mixture of polyolefin andglass fibers. In some embodiment, the electron flow is enhanced byproviding a mat having a conductive surface or surfaces and/or otherconductive pathway. The enhanced electron flow extends the battery'slife, especially in lead acid batteries where continual discharge andrecharge of the battery results in degradation of the battery'selectrodes. For example, during discharge of the lead acid battery, leaddioxide (a good conductor) in the positive electrode plate is convertedto lead sulfate, which is generally an insulator. The lead sulfate canform an impervious layer or layers encapsulating the lead dioxideparticles, which may limit the utilization of the lead dioxide, and thusthe battery, to less than 50 percent of capacity, and in some casesabout 30 percent. The insulative lead sulfate layer may also lead tohigher resistance for the battery. The effect may be a decrease in theelectrical current provided by the battery and/or in the discharge lifeof the battery. The conductive reinforcement mat may replace other platereinforcement means, such as paper, that are currently used in lead-acidor other batteries. The conductive reinforcement mat provides severaladvantages over the current plate reinforcement means, such as notdissolving in the electrolyte (e.g., sulfuric acid); providing vibrationresistance, reducing plate shedding, strengthening or reinforcing theplate; and/or providing good dimensional stability, which may alloweasier guiding or handling during battery plate manufacturing processes.

In regards to the conductive properties of the conductive reinforcementmat, the electrically conductive surface of the mat may provide anadditional route for electron flow. The route provided by the mat istypically separate from the route provided by the conductor plate orgrid of the battery. The multiple electron paths (e.g., the mat andconductor plate) allows the electrons to flow via either or both theconductive reinforcement mat or the conductor plate/grid depending onwhich route provides the least electrical resistance. In this manner, asthe electrode degrades due to formation of lead sulfate, numerous routesfor the electrons are maintained, thereby extending the overall life ofthe battery. In some embodiments, the battery may include a batteryseparator that also includes a conductive material. The batteryseparator may provide extra electron flow routes in addition to thefiber mat and conductor plate or grid.

The conductive reinforcement mat also provides excellent plate orelectrode reinforcement due to their excellent strength properties. Theconductive reinforcement mat may also have a relatively small ordecreased mat size. The relatively thin fiber mats reduce the overallvolume that the mat occupies, which allows an increased amount ofelectrolyte and/or active material paste to be used within the lead-acidbattery. The thinner mats also improve processing efficiency byincreasing the mat footage on the processing rolls, which reduces thefrequency of roll changing. In some embodiments, the conductivereinforcement mat may be less than 10 mils thick (i.e., 0.010 inches),and more commonly less than 9 mils thick (i.e., 0.009 inches). In oneembodiment, the conductive reinforcement mat is about 6 mils and 8 milsor between about 6 mils and 7 mils thick.

In some embodiments, the conductive reinforcement mats may include acombination of electrically insulative fibers and a conductive material.The electrically insulative fibers may have an electrical resistancegreater than about 1 million ohms per square. In one embodiment, theelectrically insulative fibers may include glass fibers, polyolefinfibers, polyester fibers, and the like. For convenience in describingthe embodiments, the disclosure herein will described mainly glassfibers, although it should be realized that other electricallyinsulative fibers may be used.

The electrically conductive material may include a layer or mat ofconductive fibers or a layer of other conductive materials, such as ametallic sheet or film that is positioned atop the electricallyinsulative fiber layer. In many embodiments, the conductive material isa non-metal material. In some embodiments, the conductive material mayinclude a coating of conductive material applied to or atop the fibermat. In a specific embodiment, the conductive material may be added to abinder material that is applied to the plurality of insulative fibersduring manufacture of the fiber mat, or that is sprayed atop apreviously manufactured fiber mat. The conductive material may includeconductive polymers (e.g., polyanilines), carbon material (e.g., carbonblack, activated carbon, graphite, carbon nanofibers, carbon nanotubes,graphene, CNS (carbon nanostructure)), and the like. In a specificembodiment, the conductive material may include conductive fibers thatare disposed at least partially within and/or entangled with a fiber mathaving the insulative fibers. The conductive fibers may be mixed withthe insulative fibers (e.g., glass fibers, polymeric fibers, and thelike) to make a mat that is conductive. In an exemplary embodiment,graphene or CNS may be used due to their high electrical conductivityand inertness to sulfuric acid. CNS may be more commonly used since itcan be readily dispersed in water.

The conductive reinforcement mat is typically positioned within thebattery so that the electrically conductive material/layer contacts theactive paste of the battery's electrodes. The conductive layer mat maybe disposed across substantially the entire surface of the conductivereinforcement mat so that the electrically conductive layer issubstantially equal in size and shape to the conductive reinforcementmat. In this manner the electrically conductive layer provides a largeconductive surface that contacts the electrode.

The conductive reinforcement mats may have a total tensile strength ofat least 30 lbs/3 inch and more commonly at least 35 lbs/3 inch. Toachieve this tensile strength, the nonwoven fiber mat may have a tensilestrength in the machine direction of at least 22 lbs/3 inch and atensile strength in the cross-machine direction of at least 13 lbs/3inch. The description of “lbs/3 inch” generally refers to a method oftesting the mat strength where a 3 inch by 12 inch rectangular piece ofthe fiber mat is subjected to a tensile stress until the mat fails, suchas by ripping or tearing. Mats having tensile strengths less than 22lbs/3 inch in the machine direction and less than 13 lbs/3 inch in thecross-machine direction may not have sufficient strength to withstandwinding and rewinding during processing and/or to reinforce plates of alead-acid or other battery.

In some embodiments, the conductive reinforcement mats may include ablend of two or more different sized coarse diameter fibers. Thedescription of coarse diameter fibers generally includes fibers rangingin diameter between about 6 μm and about 22 μm in one embodiment, andbetween about 8 μm and about 20 μm in another embodiment. For example,in one embodiment, a conductive reinforcement mat may include a blend offirst glass fibers having fiber diameters in the range of between 6 μmand 11 μm and second glass fibers having fiber diameters in the range ofbetween 10 μm and 20 μm. In one embodiment, the nonwoven fiber matsinclude at least 25% of each of the first and second glass fibers. Theglass fibers typically have fiber lengths that range between about ⅓ ofan inch to about 1½ inches, although fiber lengths are more commonlyabout ⅓ inch to ¾inch or 1 inch.

The conductive reinforcement mats also include a binder that bonds theglass fibers together, and that bonds the conductive fibers to the glassfibers when conductive fibers are employed as the conductive material.The binder is typically applied to the glass fibers so that the bindercomprise between about 10% and 45% by weight of the conductivereinforcement mats, between about 15% and 35% by weight of theconductive reinforcement mats, and more commonly comprises between about20% and 30% by weight of the conductive reinforcement mats. The binderis generally a chemically-resistant binder (e.g., an acrylic binder)that delivers the durability to survive in the acid environmentthroughout the life of the battery and the strength to survive the platepasting operation. In a specific embodiment, the binder may also includethe conductive material. For example, the conductive material (e.g.,graphene and the like) may be dispersed within the binder.

According to one embodiment, a fiber mat (e.g., glass fiber mat) may becoated with the conductive material to form the conductive reinforcementmat. This may be achieved via dip-coating, curtain coating, spraying,dip-and-squeeze techniques, and the like. In another embodiment, theconductive material may be mixed with the binder and applied on thefiber mat during the binder application. The latter process represents a“one-step” or single application process. The binder may help bond theconductive material to the mat. Having described several embodiments ofthe invention, additional aspects will be more apparent with referenceto the figures described below.

In some embodiments, the conductive material of the reinforcement matmay be non-metal. The non-metal conductive material coated mat may beused for reinforcing electrode plates and can provide benefits describedherein, such as improving electron transfer and current output, reducinginternal resistance of the battery, improving charging acceptance, andthe like. It is believed that by using a non-metal conductive materialcoated mat either as a separator support mat or plate reinforcement mat,the electrons do not have to go through the electrode spot where ahigher resistance exists (e.g., due to micro-cracks and the like). Theelectrons can flow freely on the conductive surface of the mat andchoose the contacting spot having minimum resistance. This benefitbecomes more pronounced after the battery is used for an extend periodof time.

FIGS. 1 and 2, respectively, show a perspective exploded view of alead-acid battery cell 200 and a cross-section assembled view of thelead-acid battery cell 200. Each cell 200 may provide an electromotiveforce (emf) of about 2.1 volts and a lead-acid battery may include 3such cells 200 connected in series to provide an emf of about 6.3 voltsor may include 6 such cells 200 connected in series to provide an emf ofabout 12.6 volts, and the like. Cell 200 includes a positive plate orelectrode 202 and a negative plate or electrode 212 separated by batteryseparator 220. Positive electrode 202 includes a grid or conductor 206of lead alloy material. A positive active material 204, such as leaddioxide, is typically coated or pasted on grid 206. Grid 206 is alsoelectrically coupled with a positive terminal 208. Grid 206 providesstructural support for the positive active material 204 along withelectrical conductivity to terminal 208.

Likewise, negative electrode 212 includes a grid or conductor 216 oflead alloy material that is coated or pasted with a negative activematerial 214, such as lead. Grid 216 is electrically coupled with anegative terminal 218. Like grid 206, grid 216 structurally supports thenegative active material 214 along with providing electrical conductanceto terminal 218. Positive electrode 202 and negative electrode 212 areimmersed in an electrolyte (not shown) that may include sulfuric acidand water. Battery separator 220 is positioned between positiveelectrode 202 and negative electrode 212 to physically separate the twoelectrodes while enabling ionic transport, thus completing a circuit andallowing an electronic current to flow between positive terminal 208 andnegative terminal 218. Separator 220 typically includes a microporousmembrane (i.e., the solid black component), which is often a polymericfilm having negligible conductance. The polymeric film may includemicro-sized voids that allow ionic transport (i.e., transport of ioniccharge carriers) across separator 220. In one embodiment, themicroporous membrane or polymeric film may have a thickness of 50micrometers or less, and preferably 25 micrometers or less, may have aporosity of about 50% or 40% or less, and may have an average pore sizeof 5 micrometers or less and preferably 1 micrometer or less. Thepolymeric film may include various types of polymers includingpolyolefins, polyvinylidene fluoride, polytetrafluoroethylene,polyamide, polyvinyl alcohol, polyester, polyvinyl chloride, nylon,polyethylene terephthalate, and the like. Separator 220 may also includeone or more fiber mats that are positioned adjacent one or both sides ofthe microporous membrane/polymeric film to reinforce the microporousmembrane and/or provide puncture resistance.

Positioned near a surface of negative electrode 212 is a nonwoven fibermat 230 (referred to herein as a reinforcement mat). Reinforcement mat230 is disposed partially or fully over the surface of negativeelectrode 212 so as to partially or fully cover the surface. As shown inFIGS. 3A-3C, a reinforcement mat 230 may be disposed on both surfaces ofthe negative electrode 212, or may fully envelope or surround theelectrode. Likewise, although reinforcement mat 230 is shown on theouter surface of the electrode 212, in some embodiments reinforcementmat 230 may be positioned on the inner surface of the electrode 212(i.e., adjacent separator 220). Reinforcement mat 230 reinforces thenegative electrode 212 and provides an additional supporting componentfor the negative active material 214. The additional support provided byreinforcement mat 230 may help reduce the negative effects of sheddingof the negative active material particles as the active material layersoftens from repeated charge and discharge cycles. This may reduce thedegradation commonly experienced by repeated usage of lead-acidbatteries.

Reinforcement mat 230 is often impregnated or saturated with thenegative active material 214 so that the reinforcement mat 230 ispartially or fully disposed within the active material 214 layer.Impregnation or saturation of the active material within thereinforcement mat means that the active material penetrates at leastpartially into the mat. For example, reinforcement mat 230 may be fullyimpregnated with the negative active material 214 so that reinforcementmat 230 is fully buried within the negative active material 214 (i.e.,fully buried within the lead paste). Fully burying the reinforcement mat230 within the negative active material 214 means that the mat isentirely disposed within the negative active material 214. In oneembodiment, reinforcement mat 230 may be disposed within the negativeactive material 214 up to about a depth X of about 20 mils (i.e., 0.020inches) from an outer surface of the electrode 212. In otherembodiments, the glass mat 230 may rest atop the negative activematerial 214 so that the mat is impregnated with very little activematerial. Often the reinforcement mat 230 will be impregnated with thenegative active material 214 so that the outer surface of the mat formsor is substantially adjacent the outer surface of the electrode 212 (seereinforcement mat 240). In other words, the active material may fullypenetrate through the reinforcement mat 230 so that the outer surface ofthe electrode 212 is a blend or mesh of active material andreinforcement mat fibers.

Reinforcement mat 230 may include a conductive material so as to makereinforcement mat 230 electrically conductive. For example, a conductivelayer may be formed on one or more sides of reinforcement mat 230 byapplying a conductive material to the surface of reinforcement mat 230.The conductive layer may be positioned to face and contact electrode 212to provide electrical pathways along which the electrons may flow. Theconductive material contacts the electrode 212, and more specificallythe active material of electrode 212 to enable electron flow on asurface or through reinforcement mat 230. The conductive material and/orlayer of reinforcement mat 230 may have an electrical resistance of lessthan about 100,000 ohms per square and more commonly less than about50,000 ohms per square so as to enable or enhance electron flow on thesurface of the mat 230. In some embodiments, the conductive layer ofreinforcement mat 230 may be electrically coupled with a negativeterminal 218 to provide a route or path for current flow to terminal218.

As described herein, electrons may flow along either reinforcement mat230 or grid/conductor 216 depending on which conductive surface providesan electrical path of least electrical resistance. For example,electrons proximate to terminal 218 may flow along an electrical path ofgrid/conductor 216 while electrons distal to terminal 218 may flow alongan electrical path of reinforcement mat 230 due to a buildup of leadsulfate on grid/conductor 216 at the distal location.

In one embodiment, the conductive layer of reinforcement mat 230 may beformed on a surface of electrically insulative fibers (e.g., glassfibers) by coating the conductive material onto the insulative fibers orby spraying the conductive material on the surface of reinforcement mat230. In a specific example, the conductive material may be added to aprimary binder material that is applied to the wet-laid insulativefibers to couple the fibers together. The primary binder/conductivematerial mixture and wet-laid insulative fibers may then be cured sothat the conductive material completely coats or is saturated throughoutreinforcement mat 230 to form the conductive layer. In anotherembodiment, reinforcement mat 230 may be manufactured in a standardprocess where a primary binder without the conductive material isapplied to the wet-laid insulative fibers to couple the fibers together.The conductive material may then be dispersed in a secondary or dilutebinder that is then coated or sprayed onto the surface of reinforcementmat 230. Reinforcement mat 230 may then be cured so that the conductivematerial forms a conductive layer across the entire surface, or adefined portion, of reinforcement mat 230. In this embodiment, amajority of the conductive material may be positioned atop the surfaceof reinforcement mat 230.

In another embodiment, a reinforcement mat 230 may be manufacturedaccording to known processes. A catalyst may be subsequently added to asurface of reinforcement mat 230 and metal ions, such as copper, may begrown on the surface of the reinforcement mat via the applied catalyst.In still another embodiment, the conductive material may be added toreinforcement mat 230 via chemical vapor deposition processes.

In lead-acid battery environments, the conductive material used forreinforcement mat 230 should be relatively corrosion resistant due tothe aggressive electrochemical environment of the battery. In someembodiments, the conductive material may include a metal, a nanocarbon,graphene, graphite, a conductive polymer (e.g., polyanilines),nanocarbons or carbon nanotubes, copper, titanium oxides, vanadiumoxides, tin oxides, and the like. In a specific embodiment, theconductive material may include carbon nano-platelets, such as graphene.The graphene may be added to the primary binder or secondary/dilutebinder as described above and applied to reinforcement mat 230 (e.g., aglass or polyolefin fiber mat) between about 0.01% and 50% by weight, orin some embodiments between about 1% and 25% by weight. When cured, thecoating of graphene forms a conductive layer across the entire surface,or a defined portion, of reinforcement mat 230.

In another embodiment, the conductive layer may comprise a conductivefiber mat, foil, or screen that is positioned adjacent the surface ofreinforcement mat 230 or entangled with the electrically insulativefibers (e.g., glass fibers) of reinforcement mat 230. In one embodiment,the conductive layer may be made by coating or spraying the conductivefibers on the surface of reinforcement mat 230. In another embodiment, aconductive fiber mat may include a plurality of conductive fibersarranged in a non-woven or woven pattern and coupled together via abinder. The conductive fiber mat may be coupled with reinforcement mat230 via a binder and the like. Electrons may flow along the conductivefiber mat, foil, or screen as described herein, such as up to negativeterminal 218.

As briefly described above, reinforcement mat 230 may include aplurality of electrically insulative fibers, such as glass, polyolefin,polyester, and the like, which are primarily used to reinforce theelectrode. Because the reinforcement mat 230 is made of such insulativefibers, the reinforcement mat 230 may be essentially non-conductiveprior to or without the addition of the conductive material. Forexample, without combining or adding the conductive material/layer, thereinforcement mat 230 may have an electrical resistance greater thanabout 1 Megohm per square. In manufacturing the reinforcement mat 230,water or another liquid may be removed (e.g., via a vacuum) from asuspension of the fibers in the liquid medium. A binder may then appliedto the wet-laid non-woven glass or polyolefin fibers to formreinforcement mat 230. As described previously, in some embodiments, theconductive material or fibers may be added to the binder and/or to theliquid medium. In one embodiment, reinforcement mat 230 may have athickness of between about 50 micrometers and about 500 micrometers andhave an average pore size of between about 5 micrometers and about 5millimeters.

Referring now to FIGS. 3A-C, illustrated are variouselectrode-reinforcement mat configurations. FIG. 3A illustrates aconfiguration where an electrode 300 has a single reinforcement mat 302disposed on or near an outer surface. As described above, reinforcementmat 302 may include a conductive material and/or layer so as to enableelectron flow on a surface and/or through reinforcement mat 302 to abattery terminal. Reinforcement mat 302 may partially or fully cover theouter surface of electrode 300. The configuration of FIG. 3B is similarto that of FIG. 3A except that an additional reinforcement mat 304 isdisposed on or near an opposite surface of electrode 300 so thatelectrode 300 is sandwiched between the two glass mats, 302 and 304.Either or both reinforcement mats, 302 and 304, may include a conductivematerial and/or layer to enable electron flow to a battery terminal. Assuch, electrode 300 may be sandwiched between two conductivereinforcement mats 302 and 304. FIG. 3C illustrates a configurationwhere a reinforcement mat 306 envelopes or surrounds electrode 300.Although FIG. 3C illustrates the reinforcement mat 306 fully envelopingthe electrode 300, in many embodiments a top side or portion of the mat306, or a portion thereof, is open. Glass mat 306 may include theconductive material and/or layer as described above to enable electronflow.

Positioned near a surface of positive electrode 202 is a reinforcementmat 240. Reinforcement mat 240 may be arranged and/or coupled withpositive electrode 202 similar to the arrangement and coupling ofreinforcement mat 230 with respect to negative electrode 212. Forexample, reinforcement mat 240 may be disposed partially or fully overthe surface of positive electrode 202 so as to partially or fully coverthe surface, may be positioned on an inner surface of the electrode 202(i.e., adjacent separator 220) instead of the shown outer surfaceconfiguration, and/or may be impregnated or saturated with the positiveactive material 204 so that the reinforcement mat 240 is partially orfully disposed within the active material 204 layer. Like reinforcementmat 230, reinforcement mat 240 also provides additional support to helpreduce the negative effects of shedding of the positive active materialparticles due to repeated charge and discharge cycles.

In some embodiments, reinforcement mat 240 may include a conductivematerial and/or layer to enable electron flow on a surface and/orthrough reinforcement mat 240 to positive terminal 208. In suchembodiments, electrons may flow along either reinforcement mat 240 orgrid/conductor 206 depending on which conductive surface provides anelectrical path of least electrical resistance. For example, electronsproximate to terminal 208 may flow along an electrical path ofgrid/conductor 206 while electrons distal to terminal 208 may flow alongan electrical path of reinforcement mat 240. In some embodiments,reinforcement mat 230 and reinforcement mat 240 may both include aconductive material and/or layer to enable electron flow on or relativeto both mats.

With regarding to the reinforcement functions of reinforcement mats 230and/or 240, in some embodiments the reinforcing aspects of these matsmay be enhanced by blending fibers having different fiber diameters.Reinforcement mats 230 and 240 (referred to hereinafter as reinforcementmat 230) include a blend of two or more different diameter coarsefibers. In one embodiment, reinforcement mat 230 includes a plurality offirst coarse fibers, having fiber diameters ranging between about 6 μmand about 13 μm, between about 6 μm and about 11 μm, or between about 8μm and about 13 μm. The first coarse fibers are blended with a pluralityof second coarse fibers, having fiber diameters ranging between about 10μm and about 20 μm or between about 13 μm and about 20 μm. In anotherembodiment, reinforcement mat 230 includes a blend of first coarsefibers having fiber diameters between 6-11 μm or 8-11 μm and secondcoarse fibers having fiber diameters between 10-20 μm or 13-20 μm. Theblend of the two or more different diameter coarse fibers results in amat that is sufficiently strong to structurally support the activematerial as described above and to withstand the various platemanufacturing processes while also minimizing the thickness and overallsize of the mat. Reducing the thickness of reinforcement mat 230 whilemaintaining mat strength may be desired since reinforcement mat 230typically is an chemically inactive component and, thus, does notcontribute to the battery's electrochemical process. Reducing the volumeof reinforcement mat 230 helps minimize the battery's volume ofnon-electrochemically contributing components.

In one embodiment, reinforcement mat 230 includes a blend of between 10%and 90% of the first coarse fibers and between 10% and 90% of the secondcoarse fibers. In another embodiment, reinforcement mat 230 includes ablend of between 25% and 75% of the first coarse fibers and between 25%and 75% of the second coarse fibers. In yet another embodiment, theblend of first coarse fibers and second coarse fibers is approximatelyequal (i.e., 50% of the first and second coarse fibers).

The length of the coarse fibers may also contribute to the overallstrength of reinforcement mat 230 by physically entangling with adjacentfibers or fiber bundles and/or creating additional contact points whereseparate fibers are bonded via an applied binder. In one embodiment, thefirst and second coarse fibers have fiber lengths that range betweenabout ⅓ inch and about 1½ inches, although an upper length limit of 1¼inch is more common. This range of lengths provides sufficient matstrength while allowing the fibers to be dispersed in a white watersolution for mat processing applications. In another embodiment, thefirst and second coarse fibers have fiber lengths that range between ½and ¾ of an inch. The fibers lengths of the first coarse fibers may bedifferent than the fibers lengths of the second coarse fibers. Forexample, in one embodiment, the first fibers may have an average fiberlength of about % inch while the second coarse fibers have an averagefiber length of about ¾inch. In one embodiment, either or both the firstor second coarse fibers have an average fiber length of at least ⅓ inch,while in another embodiment, either or both the first or second coarsefibers have an average fiber length of at least ½ inch.

The type and amount of binder used to bond the first and second coarsefibers together may also contribute to the overall strength andthickness of reinforcement mat 230. As described above, the binder isgenerally a chemically-resistant binder (e.g., an acrylic binder) thatdelivers the durability to survive in the acid environment throughoutthe life of the battery, the strength to survive the plate pastingoperation, and the permeability to enable paste penetration. The bindermay also include and bond the conductive material to the first and/orsecond coarse fibers. Increased binder usage may reduce the thickness ofreinforcement mat 230 by creating more fiber bonds and densifyingreinforcement mat 230. The increased fibers bonds may also strengthenreinforcement mat 230. In one embodiment, the binder is applied to thefirst and second coarse fibers such that the binder comprises betweenabout 10% and 45% by weight of the reinforcement mat 230 or betweenabout 15% and 35% by weight of the reinforcement mat. In anotherembodiment, the binder is applied to the first and second coarse fiberssuch that it comprises between about 20% and 30% by weight of thereinforcement mat 230.

As described herein, the conductive material (e.g., graphene) may bemixed with the binder or a secondary binder and applied to the firstand/or second coarse fibers during manufacture of the reinforcement mat302 or subsequent thereto. The resulting reinforcement mat may have anelectrical resistance of less than about 100,000 ohms per square, andmore commonly less than about 50,000 ohms per square, to enable electronflow on a surface of, or through, the reinforcement mat.

The above described reinforcement mat 230 configurations provide matshaving a total tensile strength of at least 30 lbs/3 inch and morecommonly at least 35 lbs/3 inch. Specifically, the reinforcement mat 230have a tensile strength in the machine direction of at least 22 lbs/3inch and a tensile strength in the cross-machine direction of at least13 lbs/3 inch. The above described mats have been found to havesufficient strength to support the active material and to withstand thevarious stresses imposed during plate or electrode manufacturing andprocessing (e.g., pasting or applying the active material).Reinforcement mat 230 that do not have the above described tensilestrength attributes may not be sufficiently strong to support theapplied active material (e.g., prevent shedding and the like) and/or maypose processing issues, such as mat breakage when applying the activematerial (e.g., lead or lead oxide) paste on the glass mat during theplate reinforcement process.

Further, the above described reinforcement mat 230 configuration providemats that have a thickness of 10 mils or less (i.e., 0.010 inches) andmore commonly 9 mils or less (0.009 inches). In one embodiment, thereinforcement mat 230 have a thickness in the range of between about 6and 8 mils (i.e., 0.006 and 0.008 inches), and preferably about 7 mils.These mats occupy minimal space within the electrode and batteryinterior, which allows for additional electrochemically active materials(e.g., additional electrolyte and/or lead or lead oxide paste) to beincluded in the battery, thereby increasing the life and efficiency ofthe battery. The above described mats have the unique combination ofboth minimal size or thickness and strength while also beingelectrically conductive. The mats may also have a pore size that rangesbetween 50 microns-5 mm.

In some embodiments, separator 220 may also include a conductivematerial and/or layer to enable electron flow on a surface and/orthrough separator 220 to positive terminal 208 and/or negative terminal218. For example, the fiber mat or mats of separator 220 may include aconductive material and/or layer, such as within a binder of the mats,as a film, mat, or layer of conductive fibers, and/or in accordance withany embodiment described herein. In such embodiments, electrons may flowalong reinforcement mat 230, grid/conductor 216, reinforcement mat 240,grid/conductor 206, and/or separator 220 depending on which conductivepath provides the least electrical resistance. For example, electronsproximate to grid/conductor 216 may flow along grid/conductor 216 and/orreinforcement mat 230 to terminal 218 while electrons proximate toseparator 220 flow along an electrical path of separator 220 to terminal218. Similarly, electrons proximate to grid/conductor 206 may flow alonggrid/conductor 206 and/or reinforcement mat 240 to terminal 208 whileelectrons proximate to separator 220 flow along an electrical path ofseparator 220 to terminal 208. In such embodiments, the available orpossible electron paths may be greatly increased.

Processes and Methods

Referring now to FIG. 4, illustrated is a process 400 for manufacturingan electrode. The process may involve transporting a lead alloy grid 410on a conveyor toward an active material 430 applicator (e.g., lead orlead oxide paste applicator), which applies or pastes the activematerial 430 to the grid 410. A nonwoven mat roll 420 may be positionedbelow grid 410 so that a reinforcement mat is applied to a bottomsurface of the grid 410. The reinforcement mat may include a conductivematerial and/or layer as described herein. In some embodiments, thereinforcement mat may also include a blend of coarse fibers as describedherein. A second nonwoven mat roll 440 may be positioned above grid 410so that a second reinforcement mat is applied to a top surface of thegrid 410. The second reinforcement mat may also include a conductivematerial and/or layer and/or blend of coarse fibers (similar to ordifferent from reinforcement mat 420). The resulting electrode or plate450 may subsequently be cut to length via a plate cutter (not shown). Asdescribed herein, the active material 430 may be applied to the grid 410and/or top and bottom of reinforcement mats, 440 and 420, so that theactive material impregnates or saturates the mats to a desired degree.

Referring now to FIG. 5, illustrated is a method 500 of manufacturing aplate of a lead-acid battery. At block 510, a grid of lead alloymaterial is provided. The grid of lead alloy material may be either fora positive electrode (e.g., grid/conductor 206) or a negative electrode(e.g., grid/conductor 216) of a battery. At block 520, a paste of activematerial is applied to the grid of lead alloy material to form a batteryplate or electrode (i.e., negative or positive electrode). At block 530,a nonwoven fiber mat is applied to a surface of the paste of the activematerial such that the nonwoven fiber mat is disposed at least partiallywithin the paste of active material. As described herein, the nonwovenfiber mat may include a plurality of fibers, a binder material thatcouples the plurality of fibers together, and a conductive materialdisposed at least partially within the nonwoven fiber mat so as tocontact the paste of active material. The conductive material may be anymaterial described herein and/or a conductive layer that is formed onthe nonwoven fiber mat. The nonwoven fiber mat may have an electricalresistant of less than about 100,000 ohms per square to enable electronflow on a surface of the nonwoven fiber mat. In some embodiments, thenonwoven fiber mat may be disposed within the paste of active materialbetween about 0.001 inches and about 0.020 inches.

In some embodiments, the method may also include applying a secondnonwoven fiber mat to an opposite surface of the paste of activematerial so that the grid of lead alloy material is disposed between twononwoven fiber mats. The second nonwoven fiber mat may also contain aconductive material that is disposed at least partially within thesecond nonwoven fiber mat so as to contact the paste of active material.In some embodiments, the nonwoven fiber mat may have a thickness of0.009 inches or less and/or a tensile strength of at least 30 lbs/3inch.

In some embodiments, the plurality of fibers may include a blend ofcoarse fibers as previously described. For example, the plurality offibers may include first fibers having fiber diameters between about 6μm and about 11 μm and second fibers having fiber diameters betweenabout 10 μm and about 20 μm. In some embodiments, the binder may includethe conductive material. The binder may be applied to the mat betweenabout 10% and 45% by weight, between about 20% and 30% by weight, andthe like. In some embodiments, the conductive material may include aplurality of conductive fibers that are entangled with fibers of thenonwoven fiber mat.

EXAMPLES

Two reinforcement mats were prepared according to the embodimentsdescribed herein. The resistance of the mats was then measured. Themethods of manufacturing the mats and the results are provided below.

1. Reinforcement Mat Using Graphene as a Conductive Coating

To produce the grapheme conductive coating, a suspension mixture wasprepared using graphene (xGnP-M-15 from XG Sciences) and an acrylicbinder (RHOPLEX™ HA-16 from Dow Chemical). The suspension mixture wasprepared such that it contained approximately 0.5% binder and 1.5%graphene. A spray gun was then used to apply the mixture to a glass mat(Dura-Glass® mat PR-9 and B-10). The mat was then dried at 125 C forapproximately 1 hr and cured at 175 C for approximately 3 mins. Thesurface resistance was then measured and the results are provided inTable 1 below

TABLE 1 Reinforcement Mat Using Graphene as a Conductive Coating SurfaceWeight Surface Sample Sample resistivity before resistance length width(K- coating Sample (K-Ohm) (cm) (cm) Ohm/sq.) (g) Graphene % B-10 (1)1.84 14.3 12.2 1.6 0.7609 15.8% B-10 (2) 3.41 14.2 12.2 2.9 0.7643 14.5%B-10 (3) 2.25 14.2 11.9 1.9 0.7334 17.3% PR-9 (1) 13.76 14.2 12 11.60.4577 10.1% PR-9 (2) 18.26 14.2 12.3 15.8 0.4651 11.7% PR-9 (3) 5.2914.7 12.2 4.4 0.4728  8.9%

By using the graphene material, a significant weight loss of the coatingafter a standard acid test (40 wt. % sulfuric acid, 70 C for 72 hrs) wasnot exhibited or experienced. As such, the graphene coated glass matsexperience similar weight loss as uncoated glass mats. However, a slightdrop in conductivity was observed after the mat was exposed to sulfuricacid for an extended time. This slight drop in conductivity may indicatereaction between the graphene and sulfuric acid.

2. Reinforcement Mat Using CNS (Carbon Nanostructure) as a ConductiveCoating

To produce the CNS conductive coating, a suspension mixture was preparedusing CNS (from Applied Nanostructured Solutions LLC) and/or an acrylicbinder (RHOPLEX™ HA-16 from Dow Chemical). The suspension mixture wasprepared such that it contained approximately 1% binder (or no binder)and 0.5% CNS. A glass mat (Dura-Glass® mat PR-9 or uncoated polyesterspunbond mat) was placed in the mixture and water was vacuumed out. Auniform coating of the CNS was obtained. The mat was then dried at 125 Cfor approximately 1 hr and cured at 175 C for approximately 3 mins. Thesurface resistance was then measured and the results are provided inTable 2 below.

TABLE 2 Reinforcement Mat Using CNS (Carbon Nanostructure) as aConductive Coating Surface Sample Sample Surface resistance length widthresistivity CNS Sample (Ohm) (inch) (inch) (Ohm/sq.) % Comment PR-9 (1)180 14 12 154.3 2.50% With binder PR-9 (2) 65 14 14 65.0   15% Withoutbinder PR-9 (3) 53 14 14 53.0   25% With binder PR-9 (4) 50 14 14 50.0  15% Without binder PR-9 (5) 66 14 14 66.0   25% Without binderPolyester 239 13.5 13.5 239.0  0.3% With (1) binder Polyester 68 13.513.5 68.0   2% With (2) binder Polyester 132 13.5 13.5 132.0 0.66% With(2) binder

By using the CNS material, a significant weight loss of the coatingafter a standard acid test (40 wt. % sulfuric acid, 70 C for 72 hrs) wasnot exhibited or experienced. As such, the CNS coated glass matsexperience similar weight loss as uncoated glass mats. In addition, asignificant drop in conductivity was not observed after the mat wasexposed to sulfuric acid for an extended time. It is believed that sincethe CNS has the structure of a “crosslinked matrix of carbon nanotubes,”even though sulfuric acid attacks some carbon, the whole structureremains connected and, thus, the conductivity of the coating is notaffected. Given this results, CNS may be a better choice as a conductivecoating than graphene. Further, the CNS coating provides a much betterconductivity (i.e., less resistance) than graphene on non-woven mats.For example, as shown in Table 1, K-ohm units are used for grapheneresistance, whereas in Table 2, Ohm units are used for CNS resistance.

Having described several embodiments, it will be recognized by those ofskill in the art that various modifications, alternative constructions,and equivalents may be used without departing from the spirit of theinvention. Additionally, a number of well-known processes and elementshave not been described in order to avoid unnecessarily obscuring thepresent invention. Accordingly, the above description should not betaken as limiting the scope of the invention.

Where a range of values is provided, it is understood that eachintervening value, to the tenth of the unit of the lower limit unlessthe context clearly dictates otherwise, between the upper and lowerlimits of that range is also specifically disclosed. Each smaller rangebetween any stated value or intervening value in a stated range and anyother stated or intervening value in that stated range is encompassed.The upper and lower limits of these smaller ranges may independently beincluded or excluded in the range, and each range where either, neitheror both limits are included in the smaller ranges is also encompassedwithin the invention, subject to any specifically excluded limit in thestated range. Where the stated range includes one or both of the limits,ranges excluding either or both of those included limits are alsoincluded.

As used herein and in the appended claims, the singular forms “a”, “an”,and “the” include plural referents unless the context clearly dictatesotherwise. Thus, for example, reference to “a process” includes aplurality of such processes and reference to “the device” includesreference to one or more devices and equivalents thereof known to thoseskilled in the art, and so forth.

Also, the words “comprise,” “comprising,” “include,” “including,” and“includes” when used in this specification and in the following claimsare intended to specify the presence of stated features, integers,components, or steps, but they do not preclude the presence or additionof one or more other features, integers, components, steps, acts, orgroups.

What is claimed is:
 1. A lead-acid battery comprising: a positiveelectrode; a negative electrode; a separator positioned between thepositive electrode and the negative electrode so as to electricallyinsulate the positive and negative electrodes, the separator including anonwoven fiber mat that reinforces the separator; and an additionalfiber mat positioned adjacent either the positive electrode or thenegative electrode to reinforce the positive or negative electrode,wherein the fiber mat comprises: a plurality of fibers; a bindermaterial that couples the plurality of fibers together; and a conductivematerial disposed on at least one surface of the additional fiber mat orthroughout the additional fiber mat so as to contact the positive or thenegative electrode, wherein the additional fiber mat has an electricalresistant of less than about 100,000 ohms per square so as to enableelectron flow on the surface of the additional fiber mat.
 2. Thelead-acid battery of claim 1, wherein the additional fiber mat has anelectrical resistant of less than about 50,000 ohms per square.
 3. Thelead-acid battery of claim 1, wherein the separator also includes aconductive material disposed on at least one surface of the nonwovenfiber mat or throughout the nonwoven fiber mat such that the nonwovenfiber mat comprises an electrical resistant of less than about 100,000ohms per square to enable electron flow on the surface of the nonwovenfiber mat.
 4. The lead-acid battery of claim 1, wherein the conductivematerial comprises a plurality of conductive fibers that are entangledwith fibers of the additional fiber mat.
 5. The lead-acid battery ofclaim 4, wherein the binder material includes the plurality ofconductive fibers.
 6. The lead-acid battery of claim 1, wherein theplurality of fibers of the additional fiber mat comprise glass fibers.7. The lead-acid battery of claim 1, wherein the additional fiber matcomprises a first fiber mat that is positioned on a first side of thepositive electrode or the negative electrode, and wherein the lead-acidbattery further comprises a second fiber mat that is positioned on asecond side of the positive electrode or the negative electrode oppositethe first side, wherein the second fiber mat comprises a conductivematerial disposed on at least one surface of the second fiber mat orthroughout the second fiber mat such that the second fiber mat has anelectrical resistant of less than about 100,000 ohms per square toenable electron flow on the surface of the second fiber mat.
 8. A plateor electrode for a lead-acid battery comprising: a grid of lead alloymaterial; a paste of active material applied to the grid of lead alloymaterial; and a nonwoven fiber mat disposed at least partially withinthe paste of active material, the nonwoven fiber mat including: aplurality of fibers; a binder material that couples the plurality offibers together; and a conductive material disposed at least partiallywithin the nonwoven fiber mat so as to contact the paste of activematerial, the nonwoven fiber mat having an electrical resistant of lessthan about 100,000 ohms per square to enable electron flow on a surfaceof the nonwoven fiber mat.
 9. The plate or electrode of claim 8, whereinthe nonwoven fiber mat is disposed within the paste of active materialbetween about 0.001 inches and about 0.020 inches.
 10. The plate orelectrode of claim 8, wherein the nonwoven fiber mat is a first nonwovenfiber mat, and wherein the plate or electrode further comprises a secondnonwoven fiber mat disposed at least partially within the paste ofactive material on a side opposite the first nonwoven fiber mat suchthat the plate or electrode is disposed between two nonwoven fiber mats.11. The plate or electrode of claim 10, wherein the two nonwoven fibermats comprise opposite sides of a bag that encloses or envelopes thepaste of the active material and the plate or electrode.
 12. The plateor electrode of claim 8, wherein the binder is applied to the nonwovenfiber mat between about 10% and 45% by weight.
 13. The plate orelectrode of claim 12, wherein the binder includes the conductivematerial.
 14. The plate or electrode of claim 8, wherein the nonwovenfiber mat comprises fibers selected from the group consisting of: glassfibers, polyolefin fibers, and polyester fibers.
 15. The plate orelectrode of claim 8, wherein the conductive material comprises aplurality of conductive fibers that are entangled with fibers of thenonwoven fiber mat.
 16. A method of manufacturing a plate of a lead-acidbattery, the method comprising: providing a grid of lead alloy material;applying a paste of active material to the grid of lead alloy materialto form a battery plate or electrode; and applying a nonwoven fiber matto a surface of the paste of the active material such that the nonwovenfiber mat is disposed at least partially within the paste of activematerial, wherein the nonwoven fiber mat comprises: a plurality offibers; a binder material that couples the plurality of fibers together;and a conductive material disposed at least partially within thenonwoven fiber mat so as to contact the paste of active material, thenonwoven fiber mat having an electrical resistant of less than about100,000 ohms per square to enable electron flow on a surface of thenonwoven fiber mat.
 17. The method of claim 16, further comprisingapplying a second nonwoven fiber mat to an opposite surface of the pasteof active material so that the grid of lead alloy material is disposedbetween two nonwoven fiber mats.
 18. The method of claim 16, wherein thenonwoven fiber mat has a thickness of 0.009 inches or less and a tensilestrength of at least 30 lbs/3 inch.
 19. The method of claim 16, whereinthe plurality of fibers comprises first fibers having fiber diametersbetween about 6 μm and about 11 μm and second fibers having fiberdiameters between about 10 μm and about 20 μm.
 20. The method of claim16, wherein the nonwoven fiber mat is disposed within the paste ofactive material between about 0.001 inches and about 0.020 inches. 21.The method of claim 16, wherein the binder includes the conductivematerial.
 22. The method of claim 16, wherein the conductive materialcomprises a plurality of conductive fibers that are entangled withfibers of the nonwoven fiber mat.